Upper for an article of footwear

ABSTRACT

An upper for an article of footwear is disclosed. The upper can include a plurality of layers, such as an inner layer, a middle knit layer, and an outer layer. Each of the plurality of layers can provide different functionalities to the upper. The combination of the inner layer, middle knit layer, and the outer layer can be effective at transferring a load from the underfoot region to a position above the biteline.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Application No.62/539,295, filed Jul. 31, 2017, and entitled “AN UPPER FOR AN ARTICLEOF FOOTWEAR,” the entire contents of which is incorporated by referenceherein.

TECHNICAL FIELD

The present disclosure is directed to articles of footwear. Morespecifically, the present disclosure is directed to an upper thatincludes a plurality of layers, such as an inner layer, a middle knitlayer, and an outer layer.

BACKGROUND

Various conventional articles of footwear may be designed to transfer aload from the underfoot area to the biteline. However, such a designdoes not effectively transfer a load from the underfoot area to regionsbeyond the biteline.

BRIEF DESCRIPTION OF THE DRAWINGS

Illustrative aspects of the present invention are described in detailbelow with reference to the attached drawing figures, which areincorporated by reference herein and wherein:

FIG. 1 is a top and side perspective view of an upper for an article offootwear, particularly showing the lateral side and toe end, inaccordance with aspects hereof;

FIG. 2 is a top and side perspective view of the upper for an article offootwear depicted in FIG. 1, particularly showing the medial side andthe toe end, in accordance with aspects hereof;

FIG. 3 is a cross-sectional view along the cutline 3 of the upper ofFIG. 1, particularly showing three layers of the upper, in accordancewith aspects hereof;

FIG. 4 is a side perspective view of an inner layer of an upper for anarticle of footwear, in accordance with aspects hereof;

FIG. 5 is a cross-sectional view along the cutline 5 of the inner layerof FIG. 4, in accordance with aspects hereof;

FIG. 6 is a cross-sectional view along the cutline 6 of the inner layerof FIG. 4, in accordance with aspects hereof;

FIG. 7 is a top and side perspective view of a middle knit layer of anupper for an article of footwear, in accordance with aspects hereof;

FIG. 8 is a top and side perspective view of an outer layer of an upperfor an article of footwear, in accordance with aspects hereof;

FIG. 9 is a top and side perspective view of a middle knit layer of anupper with an inner layer of the upper positioned inside the middle knitlayer, in accordance with aspects hereof;

FIG. 10 is a top and side perspective view of an outer layer of an upperpositioned over a middle knit layer of the upper, in accordance withaspects hereof;

FIG. 11 is a top and side perspective view of an upper for an article offootwear being placed on a last, in accordance with aspects hereof;

FIG. 12 is a top and side perspective view of an upper positioned on alast, in accordance with aspects hereof;

FIG. 13 is a cross-sectional view along the cutline 13 depicted in FIG.12, particularly showing an inner layer, a middle knit layer, and anouter layer of the upper, in accordance with aspects hereof;

FIG. 14 is a top and side perspective view of an upper positioned on alast with a protective sheath positioned over the upper, in accordancewith aspects hereof;

FIG. 15 is a cross-sectional view along the cutline 15 depicted in FIG.14, particularly showing the protective sheath positioned over an outerlayer, which is positioned over a middle knit layer, which is positionedover an inner layer, in accordance with aspects hereof;

FIG. 16 is a side view of a lasted upper with a compression materialcompressed against the outer surface of the lasted upper, in accordancewith aspects hereof;

FIG. 17A is a side view of an upper and a bottom unit for securing tothe underfoot portion of the upper, in accordance with aspects hereof;

FIG. 17B is a side view of the upper of FIG. 17A, with the bottom unitsecured to the underfoot portion of the upper, in accordance withaspects hereof;

FIG. 18 is a side view of an upper and a bottom unit for securing to theunderfoot portion of the upper, with the bottom unit comprising outwardextending traction elements, in accordance with aspects hereof; and

FIG. 19 is a schematic diagram of a method for manufacturing an upperfor an article of footwear, in accordance with aspects hereof.

DESCRIPTION

The subject matter of the present invention is described withspecificity herein to meet statutory requirements. However, thedescription itself is not intended to limit the scope of thisdisclosure. Rather, it is contemplated that the disclosed subject mattermight also be embodied in other ways, to include different steps orcombinations of steps similar to the ones described in this document, inconjunction with other present or future technologies. Moreover,although the terms “step” and/or “block” might be used herein to connotedifferent elements of methods employed, the terms should not beinterpreted as implying any particular order among or between varioussteps herein disclosed unless and except when the order of individualsteps is explicitly stated.

In general, aspects herein are directed to an upper for an article offootwear. In aspects, at a high level, the upper can include an innerlayer, a middle layer, and an outer layer. In such aspects, each of theinner layer, the middle layer, and the outer layer can provide differentfunctionality to the upper, and ultimately to an article of footwear.

Certain conventional uppers for an article of footwear may be designedto transfer a load from the underfoot portion to the biteline. However,such a design does not effectively transfer a load from the underfootportion to a position on the upper beyond the biteline.

The upper for an article of footwear disclosed herein alleviates thisand other problems. For example, in aspects, the upper disclosed hereinincludes a plurality of layers, which can, among other things,cooperatively transfer a load from an underfoot portion to a position onthe upper beyond the biteline.

In certain aspects, the upper disclosed herein can include an innerlayer, a middle knit layer, and an outer layer. In such aspects, theinner layer of the upper can provide certain functionalities, such aspadding, elasticity, or rigidity in specific areas. For instance, in oneaspect, the inner layer can include an increased thickness or padding inthe heel portion to provide added comfort and or support for the wearer.

In various aspects, the inner layer may include a minimal underfootportion in order to reduce the effective weight of the upper and/orarticle of footwear. In one aspect, this minimal underfoot portion caninclude a lattice-like construction reducing the overall weight of theupper, as well as reducing material and manufacturing costs.

In aspects, the middle layer of the upper can be a middle knit layer. Invarious aspects, the middle knit layer can be structurally comprised ofa knit or engineered textile. In such aspects, the middle knit layer mayresemble a sock-like structure and can provide around-the-foot supportfor a wearer. For example, in such an aspect, the middle knit layer caninclude a knit portion that covers the underfoot portion, the heelregion, the toe region, the midfoot region, and the forefoot region. Inone aspect, as discussed further below, the middle knit layer caninclude elastic properties and/or elastic materials so that the middleknit layer can provide a secure fit or feel on the wearer's foot. Inaspects, the middle knit layer can be a circular knit component or aflat knit component. In various aspects, the middle knit layer canpartly or fully cover the inner layer. In aspects, the elasticity of themiddle knit layer can facilitate compression of the inner layer upagainst the wearer's foot for a secure fit.

In various aspects, the outer layer can be compositionally comprises ofat least one thermoplastic material. In aspects, the thermoplasticmaterial can include a thermoplastic polymeric composition, which isdiscussed further below. In certain aspects, the outer layer can includean underfoot portion that can extend past the biteline. For example, inaspects, such an outer layer can facilitate transferring a structuralload from the underfoot portion to a position past the biteline, e.g.,to the midfoot and/or forefoot region, which can provide a moreresponsive and natural-feeling upper for an article of footwear.

In various aspects, as discussed further below, the outer layer can bemechanically coupled to the middle knit layer. For example, in oneaspect, the upper can be thermoformed such that the thermoplastic outerlayer melts and cools while being compressed against the middle knitlayer, which can mechanically couple together the middle knit layer andouter layer to provide a unified, responsive upper.

In one or more aspects, the outer layer can be coupled to a bottom unit,e.g., an outsole. In certain aspects, the thermoplastic material canfacilitate the coupling together of the bottom unit and the outer layer.For instance, in one aspect, the bottom unit can be coupled to the upperduring the thermoforming process, where the melted, cooled, andre-solidified thermoplastic material functions as a bonding agent bymechanically coupling the upper to the bottom unit. In alternativeaspects, a bottom unit can be coupled to the post thermoformed upper,where a separate bonding agent can be used to couple together a bottomunit to the upper.

Accordingly, in one aspect, an upper for an article of footwear isprovided. The upper has a toe end, a heel end, a medial side, a lateralside, and a biteline extending around the toe end, the medial side, theheel end, and the lateral side. The upper includes an inner layerextending to at least the toe end, the heel end, the medial side, andthe lateral side of the upper. The upper also includes a middle knitlayer extending to an underfoot portion of the upper. The middle knitlayer covers the inner layer at least at the medial side, the lateralside, the toe end, and the heel end of the upper. Further, the upperincludes an outer layer coupled with the middle knit layer. The outerlayer compositionally comprises at least one thermoplastic material. Theouter layer extends from a first position below the biteline at theunderfoot portion of the upper to a second position above the biteline,where the second position above the biteline is at least one selectedfrom a midfoot region of the upper and the toe end of the upper.

In yet another aspect, a method for manufacturing an upper for anarticle of footwear is provided. The upper has a toe end, a heel end, amedial side, a lateral side, and a biteline extending around the toeend, the medial side, the heel end, and the lateral side. The methodincludes receiving an upper. The upper includes an inner layer extendingto at least the toe end, the heel end, the medial side, and the lateralside of the upper. The upper also includes a middle knit layer extendingto an underfoot portion of the upper. The middle knit layer is adjacentthe inner layer at least at the medial side, the lateral side, the toeend, and the heel end of the upper. Further, the upper includes an outerlayer that is adjacent to at least a portion of the middle knit layer.The outer layer compositionally comprises at least one thermoplasticmaterial. The outer layer extends from a first position below thebiteline at the underfoot portion of the upper to a second positionabove the biteline, where the second position above the biteline is atleast one selected from a midfoot region of the upper and the toe end ofthe upper. The method also includes placing the upper on a form.Additionally, the method includes exposing the upper to a thermal energysource while the upper is positioned on the form.

Turning now to the figures, and FIGS. 1-3 in particular, one aspect ofan upper 100 for an article of footwear is depicted. Throughout thisdescription, various portions of the upper 100 or another upper may bereferenced. In exemplary aspects, these portions of the upper 100 arehighlighted in FIGS. 1, 2, and/or 3 with the following names or regions,and associated reference numerals: a toe end 102, a heel end 104, amedial side 106, a lateral side 108, a medial midfoot region 107, alateral midfoot region 109, an underfoot portion 110, a forefoot portion112, an ankle collar 116, and a void 118. As can also be seen in FIGS. 1and 2, a biteline 114 in phantom is depicted. The biteline 114 is theinterface where the top portion of bottom unit meets the upper, which isalso depicted in FIG. 17B (e.g., not in phantom).

In aspects, the upper 100 can include an inner layer 200, a middle knitlayer 300, and an outer layer 400, as can be best seen in FIG. 3, whichdepicts a cross-sectional view along the cutline 3 in the toe end 102 ofthe upper 100 of FIG. 1. In the views of the upper 100 depicted in FIGS.1 and 2, the inner layer 200 is not visible as it is positioned insidethe middle knit layer 130.

In the aspect depicted in FIG. 4, the inner layer 200 can include a void214 for receiving a wearer's foot. Further, the inner layer 200 depictedin FIG. 1, includes an inner surface 216 that may contact the wearer'sfoot when received within the void 214. The inner layer 200 alsoincludes an outer surface 218 opposite the inner surface 216. The innerlayer 200 depicted in FIG. 4 can generally extend from the heel end 204to the toe end 202 on the medial side 206 and the lateral side 208. Inaspects, the inner layer 200 can include an opening 220 in the forefootregion 212. The inner layer 200 can also include a row of apertures 226on the lateral side 208 that extend from the inner surface 216 to theouter surface 218, which can function as eyestays. A similar row ofapertures may also be present on the medial side 206.

In certain aspects, as discussed above, it may be desirable to reducethe overall weight of the upper 100, or to minimize the manufacturingand/or material costs. In such aspects, the inner layer 200 of the upper100 may include a minimal underfoot portion or may not include anunderfoot portion at all. For example, in aspect depicted in FIG. 3, theinner layer 200 is generally absent in the underfoot portion 110, exceptfor the minimal portions 228 and 230 that extend below the biteline 114on the medial and lateral sides 106 and 108, respectively. In one ormore aspects, the inner layer 200 may include an underfoot portion inthe form of a lattice structure in order to allow further couplingbetween the medial side 106 and the lateral side 108 in the underfootregion, while still minimizing the weight of the upper and/or reducingthe material costs.

In various aspects, the inner layer 200 can be any type of materialincluding a knit textile, a braided textile, a woven textile, and anon-woven textile, a film, a sheet, or a molded article, such as aninjection molded article, a foamed material, or a combination thereof.In the same or alternative aspects, the inner layer 200 can includenatural materials, synthetic materials, or a combination of natural andsynthetic materials. In an exemplary aspect, the inner layer 200 caninclude a non-woven textile. In various aspects, the inner layer 200 mayinclude multiple pieces of one or more materials that are securedtogether, e.g., by bonding or stitching.

As discussed above, in various aspects, the inner layer 200 can providecertain functional characteristics or properties to the upper 100. Forexample, in certain aspects, the inner layer 200 can include a pluralityof apertures 222 and 224 to allow for increased breathability. In theaspect depicted in FIG. 4, the plurality of apertures 222 can bepositioned on the lateral side 208 of the inner layer 200 and can extendfrom the inner surface 216 through the outer surface 218 of the innerlayer 200. In certain aspects, the plurality of apertures 224 can bepositioned on the medial side 206 of the inner layer 200 and can alsoextend from the inner surface 216 through the outer surface 218 of theinner layer 200.

As discussed above, the inner layer 200 can include padding in order toprovide stability or comfort for the wearer. As can be seen in FIGS.4-6, the inner layer 200 in the heel region 204 has an increasedthickness t₁ between the inner surface 216 and the outer surface 218 ofthe inner layer 200 compared to the thickness t2 between the innersurface 216 and the outer surface 218 in the lateral midfoot region 209.The padding 232 provided in the heel region 204 that provides for anincreased thickness can be formed from any type of material, such as thematerials mentioned above that may form the inner layer 200.

Turning now FIG. 7, which depicts one aspect of a middle knit layer 300utilized in the upper 100. In aspects, the middle knit layer 300 caninclude an inner surface 320 (e.g., facing the inner layer 200) and anopposing outer surface 322 (e.g., facing the outer layer 400).

In various aspects, the middle knit layer 300 can be structurallycomprised of a knitted or engineered textile. In aspects where themiddle knit layer 300 is structurally comprised of a knitted textile,the middle knit layer 300 may be formed as an integral one-piece elementduring a knitting process, such as a weft knitting process (e.g., with aflat knitting machine or circular knitting machine), a warp knittingprocess, or any other suitable knitting process. That is, the knittingprocess may substantially form the knit structure of the middle knitlayer 300 without the need for significant post-knitting processes orsteps. Alternatively, two or more portions of the middle knit layer 300may be formed separately and then attached. In some embodiments, themiddle knit layer 300 may be shaped after the knitting process to formand retain the desired shape of the middle knit layer 300 (for example,by using a foot-shaped last). The shaping process may include attachingthe middle knit layer 300 to another object (e.g., a strobel) and/orattaching one portion of the knitted component to another portion of theknitted component at a seam by sewing, by using an adhesive, or byanother suitable attachment process.

In the aspect depicted in FIG. 7, the middle knit layer 300 can besock-like in that the middle knit layer 300 can substantially cover awearer's foot. In aspects, the middle knit layer 300 can extend from thetoe end 302 to the heel end 304, and from the underfoot portion 310 upthe medial side 306 to a void 324 (and up the lateral side 308 to thevoid 324). In the same or alternative aspects, the middle knit layer 300may also cover at least a portion of the forefoot region 312.

The middle knit layer 300 may provide the upper 100 with advantageouscharacteristics including, but not limited to, a particular degree ofelasticity (for example, as expressed in terms of Young's modulus),breathability, bendability, strength, moisture absorption, weight, andabrasion resistance. In such aspects, these characteristics may beaccomplished by selecting a particular single layer or multi-layer knitstructure (e.g., a ribbed knit structure, a single jersey knitstructure, or a double jersey knit structure), by varying the size andtension of the knit structure, by using one or more yarns formed of aparticular material (e.g., a polyester material, a monofilamentmaterial, or an elastic material such as spandex), by selecting yarns ofa particular size (e.g., denier), or a combination thereof.

In various aspects, the middle knit layer 300 may also provide desirableaesthetic characteristics by incorporating yarns having different colorsor other visual properties arranged in a particular pattern. In suchaspects, the yarns and/or the knit structure of the middle knit layer300 may be varied at different locations such that the middle knit layer300 has two or more portions with different properties (e.g., a portionforming the forefoot area of the upper may be relatively elastic whileanother portion may be relatively inelastic).

In various aspects, the middle knit layer 300 may incorporate one ormore materials with properties that change in response to a stimulus(e.g., temperature, moisture, electrical current, magnetic field, orlight). For example, the middle knit layer 300 may include yarns formedof a thermoplastic polymer material (e.g., polyurethanes, polyamides,polyolefins, and nylons) that transitions from a solid state to asoftened or liquid state when subjected to certain temperatures at orabove its melting point and then transitions back to the solid statewhen cooled. In such aspects, the thermoplastic polymer material mayprovide the ability to heat and then cool a portion of the knittedcomponent to thereby form an area of bonded or continuous material thatexhibits certain advantageous properties including a relatively highdegree of rigidity, strength, and water resistance, for example.

In some aspects, the middle knit layer 300 may include one or more yarnsor strands that are at least partially inlaid or otherwise insertedwithin the knit structure of the knitted component during or after theknitting process, herein referred to as “tensile strands.” The tensilestrands may be substantially inelastic so as to have a substantiallyfixed length. The tensile strands may extend through a plurality ofcourses of the middle knit layer or through a passage within the knittedcomponent and may limit the stretch of the knitted component in at leastone direction. For example, the tensile strands may extend approximatelyfrom a biteline of the upper to a forefoot region of the upper to limitthe stretch of the upper in the lateral direction. The tensile strandsmay form one or more lace apertures for receiving a lace and/or mayextend around at least a portion of a lace aperture formed in the knitstructure of the knitted component.

In certain aspects, as best seen in FIG. 9, the middle knit layer 300can substantially encompass the inner layer 200 (depicted in phantom).In various aspects, the middle knit layer 300 can be coupled to theinner layer 200 using any conventional techniques, such as stitching orbonding. In one aspect, the middle knit layer 300 and the inner layer200 may be coupled, e.g., through stitching or bonding, to one anotherat a row of apertures 326 on the middle knit layer 300, which mayfunction as eyestays. In such an aspect, similar apertures from theinner layer 200, e.g., the apertures 226, may coincide with theapertures 326 to allow for one or more combined apertures, therebyfacilitating the use of these apertures 326 and 226 as eyestays.

In the same or alternative aspects, the middle knit layer 300 and theinner layer 200 may be coupled to one another at certain positions whilebeing uncoupled at other positions or regions. For instance, in oneaspect, the middle knit layer 300 may be coupled to the inner layer 200at or near the underfoot portion 310 and/or at or near the apertures326, with no coupling in the lateral midfoot region 309 of the middleknit layer 300. In such an aspect, the uncoupled regions can allow forstretching and movability of the layers 200 and 300 with respect to oneanother, while the inner layer 200 and the middle knit layer 300 arestill anchored together at the coupled regions.

In certain aspects, as discussed above, the middle knit layer 300 mayexhibit elastic properties, which may apply a compressive force on theinner layer 200 to provide a secure and snug fit, as well as a moresecure interface between the inner layer 200 and the middle knit layer300, e.g., by increased friction between the layers.

Turning now to FIG. 8, the outer layer 400 is depicted in isolation. Theouter layer 400 of FIG. 8 is depicted prior to being thermoformed. Asdiscussed above and below, the upper manufacturing process disclosedherein includes thermoforming the layers of the upper to form the finalupper 100 depicted in FIGS. 1-3. In aspects, the outer layer 400 caninclude a thermoplastic polymeric composition. In such aspects, thethermoplastic polymeric composition can include one or more ofpolyurethanes, polyamides, polyolefins, or nylons that transition whenthermoformed. As used herein, “thermoforming” refers to a process forturning a thermoplastic composition from a solid state to a softened orliquid state when subjected to certain temperatures at or above itsmelting point and then transitions back to the solid state when cooled.

As can be seen in the thermoplastic outer layer 400 depicted in FIG. 8,the thermoplastic outer layer 400 can extend along the entire underfootportion 410. In the same or alternative aspects, the thermoplastic outerlayer 400 can also encompass the toe end 402. For example, in the aspectdepicted in FIG. 4, the thermoplastic outer layer 400 can extend fromthe underfoot region 410 up the lateral side 408 and over the toe end402 and continue to the medial side 406 and down again to the underfootregion 410. Stated differently, the thermoplastic outer layer 400 can bewrapped around the toe end 402. In such aspects, the thermoplasticmaterial in this portion of the toe end 402 can provide stability andrigidity, as well as function as a moisture barrier.

In the aspect depicted in FIG. 8, the outer layer 400 extends around theheel end 404. In certain aspects, in the heel end 404, the outer layer400 extends from the underfoot region 410 up towards the ankle collar(e.g., the ankle collar 116 of the upper 100 of FIG. 1). In such anaspect, the thermoplastic material positioned in the heel end 404 canprovide stability to the heel region of a wearer, in addition tofunctioning as a moisture barrier.

As discussed above, in certain aspects, the uppers disclosed herein canprovide for effective load transfer from the underfoot region, e.g., theunderfoot region 410, to a position past the biteline 114. For instance,as can be seen in FIG. 8, the outer layer 400 extends along theunderfoot region 410 and up along the lateral side 408 to the apertures414, which can function as eyestays, and up along the medial side 406 tothe apertures 416, which can also function as eyestays. In such aspects,this continuity of the outer layer 400 can facilitate the transfer of aload from the underfoot region 410 to the medial midfoot region 407and/or over the toe end 402, for example.

It should be understood that the particular positioning of the outerlayer 400 depicted in FIG. 8 is just one aspect of the thermoplasticouter layer 400 for use in the uppers disclosed herein. Alternativepatterns or positioning of the outer layer 400 are also contemplated foruse in the uppers described herein. For instance, in certain aspects,the underfoot region 410 and/or the toe end 402 may be partly coveredwith the outer layer 400. In an alternative aspect, the outer layer 400may substantially encompass the middle knit layer 300.

In the aspect depicted in FIG. 8, the outer layer 400 is comprised ofmultiple pieces of material that are coupled together. For example, theouter layer 400 includes at least one piece 418 extending along theunderfoot region 410 that is coupled to another piece 420 that extendsfrom the heel end 404 to the toe end 402 and up to the eyestays 414 and416. In such an aspect, the pieces 418 and 420 can be coupled to oneanother using any conventional coupling techniques, including stitchingor adhesive bonding. In one aspect, the pieces of the outer layer, e.g.,the pieces 418 and 420, can be stitched together using a thermoplasticmaterial, e.g., a thread comprising a thermoplastic material, where sucha thermoplastic material of the thread has a melting temperature within(+/−) 20° C. of the melting temperature of the thermoplastic material ofthe outer layer. In such an aspect, upon thermoforming, the threadcomprising the thermoplastic material and the pieces 418 and 420 mayform one continuous thermoplastic piece, where the individual pieces 418and 420, and the thread comprising the thermoplastic material areindistinguishable from one another. In another aspect, a thread ormaterial can be used to secure or stitch together the pieces 418 and 420that may not melt or decompose during the thermoforming process so thatupon thermoforming the pieces 418 and 420 form one continuousthermoplastic piece with a thread embedded therein.

In aspects, the utilization of multiple pieces of a thermoplasticmaterial to form the outer layer 400 can aid in minimizing any creasesor accumulation of excess thermoplastic material when assembling theuppers disclosed herein, which can provide a more consistent and evenouter layer 400. It should be understood that while the outer layer 400depicted in FIG. 8 includes multiple pieces coupled together, in certainaspects, the outer layer 400 can be a single continuous layer ofmaterial.

In aspects, the outer layer 400 can form one continuous layer, even inaspects where the pre-thermoformed outer layer 400 included multiplepieces through the thermoforming process. For instance, during thethermoforming process, the pieces 418 and 420 would melt, flow, cool,and harden, thereby forming a continuous thermoplastic layer or film.

FIG. 10 depicts the outer layer 400 with the middle knit layer 300 inphantom. In various aspects, as discussed above and further below,during thermoforming, the outer layer 400 can melt or deform uponheating and then solidify upon subsequent cooling. In such aspects, thethermoforming process may couple together the outer layer 400 and themiddle knit layer 300. In such an aspect, the outer layer 400 mayeffectively “shrink wrap” around the portions of the middle knit layer300 that the thermoplastic material of the outer layer 400 is in contacttherewith. Such a coupling can provide for effective load transferbetween the outer layer 400 and the middle knit layer 300.

In various aspects, in addition to the thermoformed coupling of theouter layer 400 to the middle knit layer 300, the outer layer 400 andthe middle knit layer 300 can be mechanically coupled to the inner layer200, e.g., through the coupling of the apertures 414 on the outer layer400 to the apertures 326 of the middle knit layer 300. In such aspects,the outer layer 400 and the middle knit layer 300 can ultimately becoupled to the inner layer 200 also via coupling of the apertures 226 ofthe inner layer 200 (to the apertures 326 of the middle knit layer 300and to the apertures 414 of the outer layer 400). In such an aspect,this coupling together of the layers 200, 300, and 400, allows for thetransfer of a load from the underfoot region 410 of the outer layer 400(and/or of the underfoot region 310 of the middle knit layer 300) to thefunctional inner layer 200. In one or more aspects, the outer layer 400can alternatively or additionally be coupled to the middle knit layer300 using a bonding agent and/or stitching.

As discussed above, the thermoforming process of the upper 100 includesturning a thermoplastic material or thermoplastic polymeric composition(e.g., associated with the outer layer 400) from a solid state to asoftened or liquid state when subjected to certain temperatures at orabove its melting point and then transitions back to the solid statewhen cooled. In such aspects, in order to form the upper 100 to thedesired final shape, the upper 100 can be placed on a form prior to thethermoforming process. In aspects, the form may be any shape desired ofthe final upper structure. In various aspects, the form can be a portionor all of the toe end of the upper, the heel end of the upper, themidfoot region of the upper, and/or the forefoot region of the upper. Inone aspect, the form can be a last, where the last exhibits the overallgeneral shape of a foot.

FIGS. 11-13 depict the upper 100 being placed on a last 500, as just oneexemplary form for use in the thermoforming process. It should beunderstood that the general process discussed herein with respect to theuse of a last is just one exemplary use of a form, and that other typesof forms may be used in place of a last in the thermoforming processesdiscussed herein.

In aspects, the last 500 can be formed from any material. The last 500depicted in FIGS. 11-13 is a rigid fixed-shape last 500; however, inalternative aspects the last 500 may be expandable and/or contractible.In various aspects, the last 500 is inserted into the void 118 of theupper 100 in order to position the upper 100 on the last 500, therebyforming a lasted upper 600. As can be seen in the cross-sectional viewin FIG. 13, the upper 100 (e.g., that includes the inner layer 200, themiddle knit layer 300, and the outer layer 400) wraps around the last500 to aid in forming the upper 100 into the desired shape.

In certain aspects, as discussed above, during the thermoformingprocess, at least a portion of the outer layer 400 may melt and flow. Inone or more aspects, it may be desirable to restrict the flow of themelted thermoplastic polymeric composition. In such aspects, aprotective sheath may be applied over the upper 100 positioned on a last500. For example, as can be seen in FIGS. 14 and 15, a protective sheath700 is positioned over the upper 100 positioned on the last 500. As bestseen in the cross-sectional view depicted in FIG. 15, the protectivesheath 700 is positioned adjacent the outer layer 400 with the middleknit layer 300 on the side of the outer layer 400 opposite that of theprotective sheath 700. Further, as seen in FIG. 15, the inner layer 200is positioned between the last 500 and the middle knit layer 300. Inaspects, the protective sheath 700 can be formed of an elastomericpolymeric material that would not be deformed or melt during thethermoforming process or otherwise adversely affect the thermoforming ofthe upper 100.

In aspects, the protective sheath 700 may apply a compressive force tothe outer layer 400 of the upper 100, which may aid in restricting theflow of the melted thermoplastic polymeric composition that may bepresent in the outer layer 400. This compressive force, in certainaspects, may also aid in coupling the outer layer 400 to the middle knitlayer 300. Further, in aspects, a compressive force applied by theprotective sheath 700 during the thermoforming process may aid informing the upper 100 to the desired shape and form.

In aspects, it may be desirable to increase the compressive forceapplied to the upper 100, relative to that applied by the protectivesheath 700 alone. In such aspects, as can be seen in FIG. 16, acompression material 800, e.g., a vacuum bag, can be applied to theupper 100 positioned on the last 500. In the same or alternativeaspects, the compression material 800 can be utilized in place of or incombination with the protective sheath 700. In aspects, the compressionmaterial 800 can be coupled to a valve 810 for exposing the inside ofthe compression material 800 and the upper 100 to negative pressure soas to cause the compression material 800 to apply a compressive force tothe upper 100. The compression material 800 can be made from any type ofmaterial as long as such material does not melt or deform during thethermoforming process or otherwise adversely affect the thermoforming ofthe upper 100.

As discussed above, in certain aspects, the upper, e.g., the upper 100,can be coupled to a bottom unit. In certain aspects, the bottom unit caninclude an outsole. For instance, as can be seen in FIGS. 17A and 17B, abottom unit 900 can be coupled to the underfoot region 110 of the upper100. In one or more aspects, the bottom unit 900 can include anyconventional outsole materials. In one aspect, the bottom unit 900 canbe coupled to the underfoot region 110 of the upper 100 usingconventional bonding agents.

In an alternative aspect, the bottom unit 900 can be coupled to theupper 100 utilizing the thermoplastic polymeric composition of the outerlayer 400 as a bonding agent, e.g., by applying the bottom unit 90 tothe upper 100 during the thermoforming process. For example in such anaspect, the thermoplastic polymeric composition of the outer layer 400may be melted during a heating step of the thermoforming process andthen mechanically bond to the bottom unit 900 as the thermoplasticpolymeric composition is cooled and solidified during the cooling stepof the thermoforming process.

FIG. 18 depicts another aspect of a bottom unit 1000, that can becoupled to the upper 100. In the aspect depicted in FIG. 18, the bottomunit 1000 can include a plurality of traction elements 1010. The bottomunit 1000 can be coupled to the upper 100 in a manner similar to thosedescribed above with reference to the bottom unit 900 of FIGS. 17A and17B.

FIG. 19 depicts a method 1900 for manufacturing an upper for an articleof footwear. The method 1900 can include the step 1910 of receiving anupper. In such an aspect, the upper can include any of the uppersdisclosed herein, such as the upper 100 discussed above with referenceto FIGS. 1-3. For instance, in one aspect, the upper can include aninner layer, a middle knit layer, and an outer layer. In one aspect, theinner layer can include any or all of the properties of the inner layer200 discussed above with reference to FIGS. 3-6 and 9. In aspects, theinner layer can extend to at least the toe end, the heel end, the medialside, and the lateral side of the upper.

In various aspects, the middle knit layer can include any or all theproperties of the middle knit layer 300 discussed above with referenceto FIGS. 1-3 and 7-10. In one or more aspects, the middle knit layer canextend to an underfoot portion of the upper, where the middle knit layeris adjacent the inner layer at least at the medial side, the lateralside, the toe end, and the heel end of the upper.

In aspects, the outer layer can include any or all the properties of theouter layer 400 discussed above with reference to FIGS. 1-3, 8, and 10.In certain aspects, the outer layer can be positioned over at least aportion of the middle knit layer, and can extend from a first positionbelow the biteline at the underfoot portion of the upper to a secondposition above the biteline in at least one selected from a midfootregion of the upper and the toe end of the upper.

Step 1920 of the method 1900 of FIG. 19 includes placing the upper on aform. In one aspect, the upper can be placed on a last, such as the last500 discussed above with reference to 11-13, as being one example of theform.

Step 1930 of the method 1900 of FIG. 19 includes exposing the upper to athermal energy source while the upper is on a form. In such an aspect,the thermal energy source can be any suitable thermal energy source foruse in thermoforming articles. For instance in one aspect, the thermalenergy source can be a heated medium, such as heated air or a heatedliquid. In one or more aspects, the thermal energy source can includeradiating elements and/or infrared lamps. In various aspects, thethermal energy source can be adjacent an air circulation system tocirculate heated air in order to apply even heating to the surface ofthe upper. In such aspects, the upper may be exposed to a temperaturenear or above the melting temperature of the thermoplastic polymericcomposition of the outer layer of the upper.

In various aspects, prior to exposing the upper to the thermal energysource, the upper may be covered with a protective sheath, such as theprotective sheath 700 discussed above with reference to FIGS. 14 and 15.In the same or alternative aspects, the upper may be covered with acompression material, such as the compression material 800 discussedabove with reference to FIG. 16.

In certain aspects, when the upper is exposed to the thermal energysource, a thermoplastic polymeric composition in the outer layer maymelt and flow, and the compressive force of the compression materialand/or protective sheath may compress the upper against the rigid formto a desired form, e.g., the outer shape of the form. Further, while theupper is on the form and subsequent to exposing the upper to the thermalenergy source, the upper can be exposed to a temperature below themelting temperature of the thermoplastic polymeric composition of theouter layer of the upper in order to cool and harden the upper to thefinal desired shape.

The present disclosure can be described in accordance with the followingnumbered clauses.

Clause 1. An upper for an article of footwear, the upper having a toeend, a heel end, a medial side, a lateral side, and a biteline extendingaround the toe end, the medial side, the heel end, and the lateral side,the upper comprising: an inner layer extending to at least the toe end,the heel end, the medial side, and the lateral side of the upper; amiddle knit layer extending to an underfoot portion of the upper,wherein the middle knit layer covers the inner layer at least at themedial side, the lateral side, the toe end, and the heel end of theupper; and an outer layer coupled with the middle knit layer, whereinthe outer layer compositionally comprises at least one thermoplasticmaterial, and wherein the outer layer extends from a first positionbelow the biteline at the underfoot portion of the upper to a secondposition above the biteline, wherein the second position above thebiteline is at least one selected from a midfoot region of the upper andthe toe end of the upper.

Clause 2. The upper according to clause 1, wherein the middle knit layerextends along the underfoot portion of the upper from the lateral sideto the medial side.

Clause 3. The upper according to any of clauses 1 or 2, wherein theinner layer comprises an inner surface and an opposing outer surface,wherein the inner layer has a first thickness between the inner surfaceand the outer surface in the midfoot region and a second thicknessbetween the inner surface and the outer surface in the heel end, andwherein the first thickness is less than the second thickness.

Clause 4. The upper according to any of clauses 1-3, wherein the innerlayer comprises an inner surface and an opposing outer surface, andwherein the inner layer has a first aperture extending through the innersurface and the outer surface at one selected from the medial side andthe lateral side.

Clause 5. The upper according to clause 4, wherein the second positionof the outer layer corresponds with the first aperture.

Clause 6. The upper according to any of clauses 1-5, wherein the middleknit layer is formed utilizing a circular knitting technique.

Clause 7. The upper according to any of clauses 1-6, wherein the middleknit layer is formed utilizing a flat knitting technique.

Clause 8. The upper according to any of clauses 1-7, wherein the outerlayer extends from the medial side to the lateral side across the toeend of the upper.

Clause 9. The upper according to any of clauses 1-8, wherein prior tothermoforming the upper from a first state into a second state, theouter layer of the upper in the first state comprises at least twodistinct portions secured to one another, and wherein the outer layer ofthe upper in the second state includes a continuous thermoplastic layer.

Clause 10. The upper according to clause 9, wherein the at least twodistinct portions are secured to one another utilizing a secondthermoplastic material having a melting point within (+/−) 20° C. of amelting point of the at least one thermoplastic material of the outerlayer.

Clause 11. The upper according to any of clauses 1-10, wherein prior tothermoforming the upper from a first state into a second state, theouter layer of the upper in the first state comprises: a first portioncomprising a first thermoplastic material of the at least onethermoplastic material; and a second portion that is distinct from thefirst portion, the second portion comprising a second thermoplasticmaterial of the at least one thermoplastic material, and wherein, in thesecond state, the first and second thermoplastic materials have beenmelted and set to stop flow of the first and second thermoplasticmaterials leaving no distinct structure of either the first or secondthermoplastic materials.

Clause 12. A method for manufacturing an upper for an article offootwear, the upper having a toe end, a heel end, a medial side, alateral side, and a biteline extending around the toe end, the medialside, the heel end, and the lateral side, the method comprising:receiving an upper, the upper comprising: an inner layer extending to atleast the toe end, the heel end, the medial side, and the lateral sideof the upper; a middle knit layer extending to an underfoot portion ofthe upper, wherein the middle knit layer is adjacent the inner layer atleast at the medial side, the lateral side, the toe end, and the heelend of the upper; and an outer layer that is adjacent to at least aportion of the middle knit layer, wherein the outer layercompositionally comprises at least one thermoplastic material, whereinthe outer layer extends from a first position below the biteline at theunderfoot portion of the upper to a second position above the biteline,and wherein the second position above the biteline is at least oneselected from a midfoot region of the upper and the toe end of theupper; placing the upper on a form; and exposing the upper to a thermalenergy source while the upper is positioned on the form.

Clause 13. The method according to clause 12, wherein the middle knitlayer extends along the underfoot portion of the upper from the lateralside to the medial side.

Clause 14. The method according to clause 12 or 13, wherein the outerlayer comprises at least two distinct portions secured together.

Clause 15. The method according to clause 14, wherein subsequent to theexposing the upper to a thermal energy source while the upper ispositioned on the form, the at least two distinct portions of the outerlayer form a continuous thermoplastic film.

Clause 16. The method according to clause 15, wherein the continuousthermoplastic film is coupled to at least a portion of middle knitupper.

Clause 17. The method according to any of clauses 12-16, wherein theinner layer comprises an inner surface and an opposing outer surface,and wherein the inner layer has a first aperture extending through theinner surface and the outer surface at one selected from the medial sideand the lateral side, and wherein the second position of the outer layercorresponds with the first aperture.

Clause 18. The method according to any of clauses 12-17, wherein themiddle knit layer is formed utilizing a circular knitting technique.

Clause 19. The method according to any of clauses 12-18, wherein theouter layer extends from the medial side to the lateral side across thetoe end of the upper.

Clause 20. The method according to any of clauses 12-19, wherein theexposing the upper to the thermal energy source while the upper ispositioned on the form comprises exposing the upper to a temperatureabove a melting temperature of the at least one thermoplastic material.

Clause 21. The method according to clause 20, further comprising,subsequent to the exposing the upper to the thermal energy source whilethe upper is positioned on the form, exposing the upper to a temperaturebelow the melting temperature of the at least one thermoplastic materialwhile the upper is positioned on the form.

Clause 22. The method according to any of clauses 12-21, furthercomprising placing a protective sheath over the upper while the upper ispositioned on the form, prior to the exposing the upper to the thermalenergy source while the upper is positioned on the form.

Clause 23. The method according to any of clauses 12-22, wherein theform comprises a last.

From the foregoing, it will be seen that this invention is one welladapted to attain all the ends and objects hereinabove set forthtogether with other advantages which are obvious and which are inherentto the structure.

It will be understood that certain features and subcombinations are ofutility and may be employed without reference to other features andsubcombinations. This is contemplated by and is within the scope of thedisclosure herein.

While specific elements or steps are discussed in connection to oneanother, it is understood that any element and/or steps provided hereinis contemplated as being combinable with any other elements and/or stepsregardless of explicit provision of the same while still being withinthe scope provided herein. Since many possible embodiments may be madeof the disclosure without departing from the scope thereof, it is to beunderstood that all matter herein set forth or shown in the accompanyingdrawings is to be interpreted as illustrative and not in a limitingsense.

What is claimed is:
 1. An upper for an article of footwear, the upperhaving a toe end, a heel end, a medial side, a lateral side, and abiteline extending around the toe end, the medial side, the heel end,and the lateral side, the upper comprising: an inner layer extending toat least the toe end, the heel end, the medial side, and the lateralside of the upper; a middle knit layer extending to an underfoot portionof the upper, wherein the middle knit layer covers the inner layer atleast at the medial side, the lateral side, the toe end, and the heelend of the upper; and an outer layer coupled with the middle knit layer,wherein the outer layer compositionally comprises at least onethermoplastic material, wherein the outer layer extends from a firstposition below the biteline at the underfoot portion of the upper to asecond position above the biteline, and wherein the second positionabove the biteline is at least one selected from a midfoot region of theupper and the toe end of the upper.
 2. The upper according to claim 1,wherein the middle knit layer extends along the underfoot portion of theupper from the lateral side to the medial side.
 3. The upper accordingto claim 1, wherein the inner layer comprises an inner surface and anopposing outer surface, wherein the inner layer has a first thicknessbetween the inner surface and the outer surface in the midfoot regionand a second thickness between the inner surface and the outer surfacein the heel end, and wherein the first thickness is less than the secondthickness.
 4. The upper according to claim 1, wherein the inner layercomprises an inner surface and an opposing outer surface, and whereinthe inner layer has a first aperture extending through the inner surfaceand the outer surface at one selected from the medial side and thelateral side.
 5. The upper according to claim 4, wherein the secondposition of the outer layer corresponds with the first aperture.
 6. Theupper according to claim 1, wherein the middle knit layer is formedutilizing a circular knitting technique.
 7. The upper according to claim1, wherein the middle knit layer is formed utilizing a flat knittingtechnique.
 8. The upper according to claim 1, wherein the outer layerextends from the medial side to the lateral side across the toe end ofthe upper.
 9. The upper according to claim 1, wherein prior tothermoforming the upper from a first state into a second state, theouter layer of the upper in the first state comprises at least twodistinct portions secured to one another, and wherein the outer layer ofthe upper in the second state includes a continuous thermoplastic layer.10. The upper according to claim 9, wherein the at least two distinctportions are secured to one another utilizing a second thermoplasticmaterial having a melting point within (+/−) 20° C. of a melting pointof the at least one thermoplastic material of the outer layer.
 11. Theupper according to claim 1, wherein prior to thermoforming the upperfrom a first state into a second state, the outer layer of the upper inthe first state comprises: a first portion comprising a firstthermoplastic material of the at least one thermoplastic material; and asecond portion that is distinct from the first portion, the secondportion comprising a second thermoplastic material of the at least onethermoplastic material, and wherein, in the second state, the first andsecond thermoplastic materials have been melted and set to stop flow ofthe first and second thermoplastic materials leaving no distinctstructure of either the first or second thermoplastic materials.
 12. Amethod for manufacturing an upper for an article of footwear, the upperhaving a toe end, a heel end, a medial side, a lateral side, and abiteline extending around the toe end, the medial side, the heel end,and the lateral side, the method comprising: receiving an upper, theupper comprising: an inner layer extending to at least the toe end, theheel end, the medial side, and the lateral side of the upper; a middleknit layer extending to an underfoot portion of the upper, wherein themiddle knit layer is adjacent the inner layer at least at the medialside, the lateral side, the toe end, and the heel end of the upper; andan outer layer that is adjacent to at least a portion of the middle knitlayer, wherein the outer layer compositionally comprises at least onethermoplastic material, wherein the outer layer extends from a firstposition below the biteline at the underfoot portion of the upper to asecond position above the biteline, and wherein the second positionabove the biteline is at least one selected from a midfoot region of theupper and the toe end of the upper; placing the upper on a form; andexposing the upper to a thermal energy source while the upper ispositioned on the form.
 13. The method according to claim 12, whereinthe middle knit layer extends along the underfoot portion of the upperfrom the lateral side to the medial side.
 14. The method according toclaim 12, wherein the outer layer comprises at least two distinctportions secured together.
 15. The method according to claim 14, whereinsubsequent to the exposing the upper to a thermal energy source whilethe upper is positioned on the form, the at least two distinct portionsof the outer layer form a continuous thermoplastic film.
 16. The methodaccording to claim 15, wherein the continuous thermoplastic film iscoupled to at least a portion of middle knit upper.
 17. The methodaccording to claim 12, wherein the inner layer comprises an innersurface and an opposing outer surface, wherein the inner layer has afirst aperture extending through the inner surface and the outer surfaceat one selected from the medial side and the lateral side, and whereinthe second position of the outer layer corresponds with the firstaperture.
 18. The method according to claim 12, wherein the middle knitlayer is formed utilizing a circular knitting technique.
 19. The methodaccording to claim 12, wherein the outer layer extends from the medialside to the lateral side across the toe end of the upper.
 20. The methodaccording to claim 12, wherein the exposing the upper to the thermalenergy source while the upper is positioned on the form comprisesexposing the upper to a temperature above a melting temperature of theat least one thermoplastic material, and subsequent to the exposing theupper to the thermal energy source while the upper is positioned on theform, exposing the upper to a temperature below the melting temperatureof the at least one thermoplastic material while the upper is positionedon the form.